1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing unpredictable aggregate production costs, excessive plant downtime for liner changes, or inconsistent final product gradation? Inconsistent feed material and equipment limitations directly impact your bottom line through unplanned maintenance, high wear part consumption, and suboptimal yield of highvalue product fractions. These operational challenges translate to tangible costs: hours of lost production, frequent component replacement labor, and revenue lost to offspec material.

What if your primary crushing stage could deliver greater stability to your entire circuit? How would predictable wear life and simplified maintenance affect your operational expenditure? The solution lies in specifying a crusher engineered not just for peak performance, tetapi untuk berterusan, costeffective operation under realworld conditions. This is the focus of a professionalgrade ODM stone crusher plant.

2. GAMBARAN KESELURUHAN PRODUK

This ODM (Pengeluar Reka Bentuk Asal) stone crusher plant is a stationary primary crushing solution engineered for highvolume reduction of quarried rock, Sungai kerikil, dan konkrit perobohan. It is designed as the foundational stage in aggregate production and mineral processing circuits.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Runofquarry (ROQ) material is delivered via dump truck or wheel loader into a rugged vibrating grizzly feeder.
2. PraSkrining & ByPass: The grizzly section removes natural fines and subfraction material, directing it to a bypass conveyor to reduce unnecessary load on the crusher.
3. Penghancuran utama: Oversize material is conveyed into the heavyduty jaw crusher chamber for compressive size reduction.
4. Pelepasan produk: Crushed material is discharged onto the main product conveyor for transport to secondary processing or stockpiling.

Skop Permohonan: Sesuai untuk batu keras (granit, basalt), abrasive aggregates, and recycled concrete applications in quarrying, perlombongan, and largescale construction projects.
Batasan: Not designed as a standalone finished product plant; requires secondary/tertiary stages for precise shaping or small aggregate production. Feed size is constrained by the specific model's inlet dimensions.

3. CIRI TERAS

HeavyDuty Jaw Crusher Core | Asas Teknikal: Forged Eccentric Shaft & Ruang Penghancuran Dalam | Faedah Operasi: Sustained high throughput with reduced risk of shaft failure under shock loads | Kesan ROI: Lower lifetime cost of ownership and minimized risk of catastrophic downtime
Integrated Grizzly Feeder | Asas Teknikal: Stepped grizzly bars with adjustable slope | Faedah Operasi: Effective removal of fines prior to crushing, increasing crusher capacity and reducing liner wear | Kesan ROI: Direct fuel and power savings by not processing alreadysized material; extends wear part intervals
Modular Discharge Conveyor | Asas Teknikal: Bolttogether sections with standardized idlers | Faedah Operasi: Enables rapid reconfiguration of plant layout for different site plans or future expansion | Kesan ROI: Reduces installation time/costs by up to 30% compared to welded designs
Centralized Greasing System | Asas Teknikal: Manifold with lines running to all major bearing points | Faedah Operasi: Membolehkan selamat, routine lubrication from a single station in under 10 minit | Kesan ROI: Ensures bearing longevity, prevents costly failures attributed to missed manual greasing points
Reinforced Hopper & Support Structure | Asas Teknikal: Hightensile steel plates with internal ribbing | Faedah Operasi: Withstands continuous impact from large feed material and loader operations without deformation | Kesan ROI: Eliminates structural repair costs over the plant's lifecycle

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | This ODM Stone Crusher Plant Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Kehidupan Pakai Pelapik (Batu Abrasive) | 120,000 150,000 tan | 180,000 220,000 tan | +40% penambahbaikan |
| Average Power Consumption per Ton Crushed| 0.8 1.1 kWj/tan | 0.65 0.85 kWj/tan| ~20% reduction |
| Scheduled Maintenance Downtime (tahunan) | 48 72 hours/year| 24 36 hours/year| 50% pengurangan |
| Yield of Target Fraction (mis., 150mm +50mm) | +/ 15% variance from target| +/ 8% variance from target| ~47% greater consistency |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 200 ke 800 tan per jam (Tph), depending on feed material and desired product size.
Penghancur utama: Jaw Crusher models from JC110 to JC180.
Julat Pembukaan Suapan: 750mm x 500mm up to 1200mm x 850mm.
Kuasa memandu: 90 kW kepada 160 motor elektrik kW.
Pengumpan: Getaran grizzly feeder (VGFF VGF), length from 4000mm to 6000mm.
Spesifikasi Bahan: Main frame fabrications use Q345B steel; highwear areas utilize Hardox® or equivalent abrasionresistant steel liners.
Dimensi Fizikal (Persediaan Biasa): Approximate footprint of ~25m (L) x ~8m (W) x ~7m (H). Exact dimensions are projectspecific.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Dust suppression system piping is standard; enclosures are optional.

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Cabaran: An existing quarry needed to increase primary output by overcapacity without expanding its crushing pad footprint or requiring extensive new civil works.
Solution Implementation was based on an ODM stone crusher plant featuring a deepchamber jaw crusher for higher reduction ratio and an integrated feeder prescreening system.
Results Achieved a throughput increase of35% on the same footprint while improving overall plant efficiency due to effective fines removal at the primary stage.

Urban Recycling & Demolition Hub

Challenge Processing mixed demolition waste containing rebarreinforced concrete created frequent blockages in traditional impactstyle primary units leadingto excessive downtime
Solution A robust ODM jaw crusher plant with heavyduty flywheelsand hydraulic toggle adjustmentfor uncrushable item release was deployed
Results Plant availability increasedto94%,andwearpartcostsforprimarycrushingfellby60%duetothecompressivecrushingactionbeinglesssusceptibletoabrasionfromconcretepaste

7.PERTIMBANGAN KOMERSIL

PricingforanODMstonecrusherplantisstructuredaroundcorecapacityandconfiguration:

• Peringkat Asas(200350Tph):Includesprimaryjawcrusher,VGFF VGF,basicdischargeconveyor,andmotorstarters.OptionalFeatures:DustSuppressionKit,RubberChuteLiners,AutoGreasingSystem.
• Mid Tier(350600Tph):IncludesallBaseTierfeaturesplusreinforcedstructurehydraulictoggleadjustmentonjawcrushers,andPLCcontrolwithbasicsensors.OptionalFeatures:MetalDetector,MagnetSeparator,FullyEnclosedWalkwaysServicePlatforms:
• High Tier(600+Tph):FullmodulardesignheavydutycomponentsadvancedPLCwithSCADAinterfaceandproductiontrackingOptionalFeatures:DualPowerOption(Diesel/Electric)AdvancedVibrationMonitoring

ServicePackagesareavailableasannualcontractsincludingperiodicinspectionswearpartconsumableschedulesandprioritysupportFinancingoptionsincludingleasingandrenttoownstructurescanbetailoredforcapitalexpenditureplanning

8.Soalan Lazim

Q What factors determine whether this jaw crusher plant is suitable for our specific rock type?
A The compressive strength abrasion index SiO2 contentandfeedsize distributionarecriticalOurengineeringteamrequiresasampleformaterialtestingtorecommendtheoptimalchamberdesignlinermaterialandoperationalparametersforyoursite

Q How does this plant manage variations in feed size which are common in quarry operations?
A The combinationofarobustvibratinggrizzlyfeederforprescreeningandajawcrusherawithsufficientlydeepchamberprovidesahighdegreeofforgivenessFielddatashowsconsistentthroughputevenwithfeedvarianceupto±20fromtheidealgradation

Q WhatisthetypicalleadtimefromordertocommissioningforacustomODMplant?
A Forstandardconfigurationsleadtimesrangefrom14to22weeksdependingonmodelcomplexityCustomizationssuchasspecificconveyorlengthsorspecializedsafetyaddonsmayextendthistimelineAdetailedprojectplanisprovideduponquotation

Q Arewearpartsreadilyavailableandhowarepricesstructured?
A Wearparts(jawplatescheekplatesgrizzlybars)arestockedagainstyourplantserialnumberWeofferaconsumablesupplyagreementwithfixedannualpricingwhichtypicallyresultsin1015costsavingsoverspotpurchaseswhileguaranteeingavailability

Q Whatleveloftrainingisd providedforouroperatorsandmaintenancestaff?
A ComprehensivecommissioningincludesatwodayonsitetrainingprogramcoveringnormaloperationroutinelubricationdailychecksandsafeshutdownproceduresFulldocumentationincludingpartslistsassemblydrawingsandelectricalschematicsisprovidedindigitalformat